Catalog No.: 2100.50P Effective: 11-01-99 Replaces: 6-01-99 OPERATING AND INSTALLATION INSTRUCTIONS Models 0030B, 0042B, 0066B, 0090B 0135B, 0180B Type H RESIDENTIAL BOILERS FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids or other combustible materials in the vicinity of this or any other appliance. To do so may result in an explosion or fire.
Contents 3 1. RECEIVING EQUIPMENT 3 2. GENERAL SPECIFICATIONS AND DIMENSIONS 4 4 4 4 4 5 7 10 10 14 3. INSTALLATION PROCEDURES - Code Requirements - Mounting Base - Clearance Requirements - Combustion/Ventilation Air - Venting Connections - Vent Damper Installation - Gas Supply Connections - Water Connections & System Piping - Electrical Wiring 22 22 22 23 28 28 29 4.
1. RECEIVING EQUIPMENT Follow the installation instructions furnished with the vent damper package. The plug-in connector can also be used with power venters. Refer to the specific installation instructions supplied by the power vent manufacturer. On receipt of your equipment it is suggested that you visually check for external damage to the carton. If the carton is damaged, it is suggested that a note be made on the Bill of Lading when signing for equipment.
3. INSTALLATION PROCEDURES CODE REQUIREMENTS Installation must be in accordance with local codes, or, in the absence of local codes, with the latest editions of the National Fuel Gas Code, ANSI Z223.1, and the National Electrical Code, ANSI/NFPA 70. In Canada installations must conform with the current CAN/CGA B149.1 or .2 and the Canadian Electrical Code Part 1 CSA C22.2 No.1.
2) When the boiler is installed in a confined space such as a utility room or closet (Models 0030,0042 and 0066 only), where all air is supplied from inside the building, the boiler room must be provided with two openings, each one having a minimum net free area, in square inches as follows: Model 0030, 0042 & 0066 Location of the openings is the same as in the previous case - that is, within 12 inches of the top, and within 12 inches of the bottom of the enclosure.
10’ The weight of the vent stack or chimney must not rest on boiler draft hood. Support must be provided in compliance with applicable codes. The boiler top and draft hood must be readily removable for maintenance and inspection. Vent pipe should be adequately supported to maintain proper clearances from combustible construction. Type "B" double wall (or equivalent vent pipe is recommended.
At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation. VENT DAMPER INSTALLATION LOCATION The vent damper supplied with each boiler must be located in the vent so that it serves only the appliance for which it is intended.
MOUNTING On vertical vents, the vent damper may be mounted with the actuator in any position. On horizontal vents, do not mount the actuator either directly above or directly below the vent pipe; mount the vent damper actuator to the side of the vent. The vent damper is set up for a continuous pilot system.
VENT DAMPER NORMAL OPERATION SUMMARY For safe, efficient operation, the vent damper and all flue product carrying areas of the appliance must be checked annually, with particular attention given to deterioration from corrosion or other sources. Check vent damper operation as follows: 1. When the boiler is off, check that the vent damper position indicator points to the closed position, below.
GAS SUPPLY CONNECTIONS The inlet gas connection of the boiler gas valve is 1/2". Provide an adequate gas piping supply line no smaller than 1/2", according to the chart below: The gas valve is provided with pressure taps to measure gas pressure upstream of the gas valve and downstream which is the same as the manifold pressure. Maximum Equivalent Pipe Length (Feet) WATER CONNECTIONS & SYSTEM PIPING The pipe size for water connections is shown on page 3. Typical piping systems are shown on pages 11 to 13.
Systems with multiple zones may require an additional circulator. Consult manufacturers data for valve pressure drops. When an indirect water heating system is used, it is recommended that a separate circulator be installed to meet the required flow and pressure drop conditions of the indirect water heater. We recommend that the make up water from the cold water line have a check valve, gate valve, and feedwater regulator set at 12 psig.
AIR VENT AIR SCOOP FEED VALVE DIAPHRAGM EXPANSION TANK PIPE PRESSURE RELIEF VALVE TO DRAIN ZONE VALVES COLD WATER INLET HOT WATER SUPPLY HEATING UNITS CIRCULATOR COLD WATER SUPPLY Fig.# 8998.
AIR VENT 12" MAX. AIR SCOOP DIAPHRAGM FEED EXPANSION VALVE TANK PIPE PRESSURE RELIEF VALVE TO DRAIN CIRCULATORS COLD WATER INLET HEATING UNITS MULTIPLE ZONES WITH CIRCULATORS Fig. #8999.1 AIR VENT AIR SCOOP FEED VALVE DIAPHRAGM EXPANSION TANK PIPE PRESSURE RELIEF VALVE TO DRAIN COLD WATER INLET ZONE VALVES HEATING UNITS MULTIPLE ZONES WITH ZONE VALVES Fig. #9000.
ELECTRICAL WIRING The electrical power supply requirement for these boilers is 115 volts, 60 Hz. Field wiring connections and electrical grounding must comply with the local codes, or in the absence of local codes, with the National Electrical Code, ANSI/NFPA 70-1987. Provide a separate fused circuit from the main electrical panel to the boiler, and a disconnecting means within sight of the boiler. Remove the control box cover and make the power supply connections in the field wiring compartment.
WIRING DIAGRAM: STANDING PILOT 24 V 2 STAGE MODELS 90, 135 & 180 Fig. # 2223e See page 14 wiring diagram key information.
WIRING DIAGRAM:INTERMITTENT IGNITION DEVICE (IID) MODELS 30, 42, & 66 *REFER TO INSTALLATION/OPERATING INSTRUCTIONS AND WIRING DIAGRAM SUPPLIED WITH VENT DAMPER. VENT DAMPER OPTIONAL ON CANADIAN MODELS. See page 14 wiring diagram key information.
WIRING DIAGRAM: INTERMITTENT IGNITION DEVICE (IID) MODELS 90, 135 & 180 *REFER TO INSTALLATION/OPERATING INSTRUCTIONS AND WIRING DIAGRAM SUPPLIED WITH VENT DAMPER. VENT DAMPER OPTIONAL ON CANADIAN MODELS. Fig. #2358 See page 14 wiring diagram key information.
WIRING DIAGRAM: Single Zone Taco Valve Fig. # 2228e WIRING DIAGRAM: Dual Zone Taco Valve Fig. # 2229e NOTE: Maximum three (3) zone valves per one (1) 40 VA transformer. WIRING DIAGRAM: Dual Zone Honeywell Valve Fig. # 2230e NOTE: Maximum five (5) zone valves per one (1) 40 VA Transformer.
WIRING DIAGRAM: System with (3) Zone Pumps Fig. #2232e NOTE: Check VA rating of each relay coil. Total load must not exceed VA rating of transformer. WIRING DIAGRAM: Power Vent System w/ Zone Valve Taco Zone Valve Fig. #2233e Honeywell Zone Valve Fig.
WIRING DIAGRAM: Primary/Secondary Pumping System Honeywell Zone Valve Fig. #2223.
WIRING DIAGRAM: Standing Pilot With Low Water Cut Off Device Fig. # 2223.1e Note: Low water cut off (LWCO) and system switch supplied by others. WIRING DIAGRAM: IID Units With Low Water Cut Off Device Fig. # 2357E Note: Low water cut off (LWCO) and system switch supplied by others.
4. SERVICING PROCEDURES GENERAL LOCATION OF CONTROLS CIRCULATOR VENT SENSOR CONTROL BOX COMPONENT LOCATIONS MODELS 135 & 180 2-Staged Controller BYPASS VALVE (MODELS 135 & 180 ONLY) BYPASS LINE TEMPERATURE AND PRESSURE GAUGE Relay 2-STAGED CONTROLLER (MODEL 90 ONLY) PRESSURE RELIEF VALVE RELAY ADJUSTABLE HIGH LIMIT FIELD WIRING COMPARTMENT Fast Ignition Module Response Temperature (Auto Ignition Only) Sensor Fig.# 8195.
START-UP PROCEDURES SECTION 1. Filling the System Fill system with water. Purge all air from the system using purge valve sequence. After system is purged of air, lower system pressure. Open valves for normal system operation, fill system through feed pressure regulator to minimum 12 PSI. Manually open air vent on the compression tank until water appears, then close vent. On multiple zone systems, purge each zone separately. Isolate the other zones while one zone is being purged of air.
SECTION 3. Lighting the Boiler Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI-Z21.13a 1983 Standard. CAUTION: Liquefied petroleum gas is heavier than air and sinks to the ground. Exercise extreme care in lighting boiler in confined areas.
10. Turn on all electric power to the boiler. 11. Set the thermostat to the desired setting. FOR STANDING PILOT MODELS WITH ROBERTSHAW GAS VALVE, 2 STAGE OPERATION (Models 90, 135 & 180) 1. 2. 3. 4. TO TURN OFF GAS TO THE BOILER: (Models 90, 135 & 180) STOP! Read the safety information. Set the thermostat to the lowest setting. Turn off all electric power to the boiler. Push in and move gas control lever counterclockwise to "OFF" position. 1. Set the thermostat to the lowest setting. 2.
TO TURN OFF GAS TO BOILER FOR INTERMITTENT IGNITION (IID) WITH HONEYWELL OR ROBERTSHAW GAS VALVE (For All Models) 1. 2. 3. 4. 1. Set the thermostat at the lowest setting. 2. Turn off all the electric power to the boiler if service is to be performed. 3. For Honeywell Valve: Turn gas control knob clockwise to "Off". Make sure knob rest against stop. For Robertshaw Valve: Push in and move gas control lever to "Off" position. STOP! Read the safety information above. Set the thermostat to the lowest setting.
CAUTION: Should overheating occur or the gas supply fails to shut off, DO NOT turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the boiler. Failure to observe this precaution may aggravate the overheated condition resulting in possible damage to the boiler and injury to the user. SECTION 4. Testing the Ignition Safety Shutoff.
SAFE SHUTDOWN TESTS LIMIT ACTION With the burner operating, lower the high limit setting to simulate an overheated boiler. Normal shutdown should occur. Restore the normal limit setting, and the burner should restart. FLAME FAILURE With burner operating, close the manual fuel valves to simulate a flame failure. System should lock out after safety switch timing (15 seconds).
LOW WATER CUT OFF WHEN INSTALLED The low water cut off automatically shuts down burner whenever water level drops below probe. 90 second time delay prevents premature lockout due to temporary conditions such as power failure or air pockets. Flush float type devices at beginning of each heating season. PROCEDURE FOR CLEANING FLUE GAS PASSAGE-WAYS Soot will clog areas behind fins and cause eventual tube failure. Any sign of soot at base of burners or around outer jacket indicates a need for cleaning. 1.
6. Remove combustion chamber clips at the four corners of the heat exchanger. 7. Lift heat exchanger straight up using caution not to damage refractory. 8. 9. 10. 11. 13. boiler and piping system for leaks at full line pressure. Run system circulating pump for a minimum of 1/2 hour with boiler shut-off. Shut down entire system and vent all radiation units and high points in system piping. Check all strainers for debris.
5. TROUBLE SHOOTING GUIDE IMPORTANT NOTICE These instructions are primarily intended for the use of qualified personnel specifically trained and experienced in the installation of this type of heating equipment and related system components. Installation and service personnel may be required by some states to be licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions.
10) Defective ignition module or defective gas valve. 10) Before module goes into a lock-out, check voltage across MV and MV/ PV. If no 24V is present, replace module. If 24V is present, replace gas valve. 3) Pilot Outage. (Standing pilot models) 1) Too low or too high gas pressures. 2) Restricted pilot. 3) Weak thermocouple. 1) Adjust inlet gas pressure as shown on rating plate. 2) Clean pilot orifice. 3) Replace thermocouple. 4) Yellow lazy flame. 1) Too low gas pressure.
ADJUSTMENTS/REPLACEMENTS OF COMPONENTS 3. Flame Roll-out Switch Replacement a) Shut off electrical power to the boiler. b) Remove wiring connections to switch. c) Remove screws (2) holding the switch. d) Reverse above procedure to re-install. DANGER - SHOCK HAZARD Make sure electrical power to the boiler is disconnected to avoid potential serious injury or damage to components. 4. Vent Thermal Switch Replacement a) Shut off electrical power to the boiler. b) Remove wiring connections to switch.
12. 2-Staged Controller (Models 90, 135 & 180) a) Shut off electrical power to the boiler. b) Remove control cover screws and open control compartment. c) The control is factory set at 160°F. To reset to another setting, use a small screw driver and turn dial clockwise to lower the temperature or counter-clockwise to raise the setting. d) To replace the staged controller, disconnect the wiring connections. e) Remove screws (2) holding the staged controller. f) Remove upper access panel.
4-C 2-V 1-V 5-M 3-M 2-S 6-H 1-M 3-H 2-H 1-H 9-H 1-R (30 & 42) 7-H 1-S 4-M 3-C 6-H 4-H 3-S 1-R 5-H 8-H 1-R 3-J 1-J 1-C 4-P 4-S 2-B 2-J 2-C 1-B 5-P 1-G 3-B 4-B 4-C HONEYWELL STANDING PILOT HONEYWELL IID 3-P ROBERTSHAW STANDING PILOT 3-P 1-P 1-P 1-P 2-P 2-P 6-P 8-P Fig. # 8189.3 2-P 6-P 9-P 8-P *Bypass valve supplied on sizes H-0135 and H-0180 only. 35 6-P Fig. # 9112 8-P Fig. # 8190.
BOILERS MANUFACTURED AFTER AUGUST 11, 1994 WITH SERIAL #9408116901 OR LATER, HAVE IID IGNITION IN LIEU OF HSI IGNITION.
BOILERS MANUFACTURED AFTER AUGUST 11, 1994 WITH SERIAL #9408116901 OR LATER, HAVE IID IGNITION IN LIEU OF HSI IGNITION. CALL OUT M 1-M 2-M 3-M 4-M 5-M 6-M 7-M P 1-P 2-P 3-P 4-P 5-P 6-P 8-P 8-P R 1-R S 1-S 2-S 3-S 4-S V 1-V 2-V DESCRIPTION MISCELLANEOUS PRV 30 PSI Deliming Kit T & P Gauge Drain Valve Pump Inline Taco Pump Inline Grundfos Pump Cartridge (Taco) Wire/Harness Std. Wire/Harness HSI Honeywell Wire/Harness HSI Fenwal Wire/Harness IID PILOT Pilot Nat. Std. Pilot Pro. Std. Pilot Nat.
www.raypak.com Raypak, Inc., 31111 Agoura Road, Westlake Village, CA 91361-4699 (818) 889-1500 FAX (818) 889-4522 Raypak Canada LTD, 2805 Slough Street, Mississauga, Ontario, Canada L4T 1G2 (905) 677-7999 FAX (905) 677-8036 Raypak Australia Pty. Ltd, 7 Geddes St., Mulgrave, Victoria, Australia 3170 (6139) 560 4944 FAX (6139) 560 4974 Litho in U.S.A.
